Sealant-filled enclosures and methods for environmentally protecting a connection

ABSTRACT

A sealant-filled enclosure assembly for environmentally protecting a connection between cables includes a housing and a mass of sealant. The housing is selectively configurable between an open position to receive the connection and a closed position wherein the housing defines an enclosure cavity to contain the connection. The housing includes at least one sealant cavity and a port control system. The port control system includes a gate member that is selectively deflectable from a closed position, wherein the gate member blocks a cable port, to an open position, wherein the cable port is open to permit a cable to extend into the enclosure cavity through the cable port. The gate member is rigid or semi-rigid. The mass of sealant is disposed in the at least one sealant cavity.

RELATED APPLICATION(S)

The present application claims the benefit of and priority from U.S.Provisional Patent Application Ser. No. 61/115,736, filed Nov. 18, 2008,the disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to environmentally protective enclosuresand, more particularly, to enclosures for environmentally protectingcable connections and the like.

BACKGROUND OF THE INVENTION

Sealant-filled environmentally protective enclosures are employed toprotect cable connections. Such enclosures may be used toenvironmentally protect the connections between telecommunicationssignal transmission cables, the electrical power transmission cables,etc. For example, U.S. Pat. No. 5,763,835 to Huynh-Ba et al. discloses agel-filled enclosure including a pair of cavitied bodies that arehingedly connected and closable in clam shell fashion. When theenclosure is closed about the cables, gel is typically displaced andthereby elongated and seals about a cable splice or the like.

SUMMARY OF THE INVENTION

According to embodiments of the present invention, a sealant-filledenclosure assembly for environmentally protecting a connection betweencables includes a housing and a mass of sealant. The housing isselectively configurable between an open position to receive theconnection and a closed position wherein the housing defines anenclosure cavity to contain the connection. The housing includes atleast one sealant cavity and a port control system. The port controlsystem includes a gate member that is selectively deflectable from aclosed position, wherein the gate member blocks a cable port, to an openposition, wherein the cable port is open to permit a cable to extendinto the enclosure cavity through the cable port. The gate member isrigid or semi-rigid. The mass of sealant is disposed in the at least onesealant cavity.

According to embodiments of the present invention, a method forenvironmentally protecting a connection between cables includesproviding a sealant-filled enclosure assembly including a housing and amass of sealant. The housing is selectively configurable between an openposition to receive the connection and a closed position wherein thehousing defines an enclosure cavity to contain the connection. Thehousing includes at least one sealant cavity and a port control system.The port control system includes a gate member that is selectivelydeflectable from a closed position, wherein the gate member blocks acable port, to an open position, wherein the cable port is open. Thegate member is rigid or semi-rigid. The mass of sealant is disposed inthe at least one sealant cavity. The method further includes:selectively deflecting the gate member to its open position to open thecable port; installing the connection in the enclosure cavity such thatthe cable extends into the enclosure cavity through the cable port; andclosing the housing about the connection.

According to embodiments of the present invention, a sealant-filledenclosure assembly for environmentally protecting a connection betweencables includes a housing and a mass of sealant. The housing isselectively configurable between an open position to receive theconnection and a closed position wherein the housing defines anenclosure cavity to contain the connection. The housing includes atleast one sealant cavity and a port control system. The port controlsystem includes a gate member that is selectively deflectable from aclosed position, wherein the gate member blocks a cable port, to an openposition, wherein the cable port is open to permit a cable to extendinto the enclosure cavity through the cable port. The mass of sealant isdisposed in the at least one sealant cavity. The housing defines, whenclosed, a tubular extension defining a reservoir on a side of the gatemember opposite the enclosure cavity. The tubular extension isconfigured to collect and retain in the reservoir sealant exuded fromthe enclosure cavity through the cable port.

Further features, advantages and details of the present invention willbe appreciated by those of ordinary skill in the art from a reading ofthe figures and the detailed description of the embodiments that follow,such description being merely illustrative of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a sealant-filled enclosure assemblyaccording to embodiments of the present invention in an open position.

FIG. 2 is a perspective view of a housing of the sealant-filledenclosure assembly of FIG. 1 in the open position.

FIG. 3 is a cross-sectional view of the sealant-filled enclosureassembly of FIG. 1 taken along the line 3-3 of FIG. 1.

FIG. 4 is an enlarged, fragmentary view of the housing of FIG. 2.

FIG. 5 is an enlarged, fragmentary view of the housing of FIG. 1.

FIG. 6 is a perspective view of the sealant-filled enclosure assembly ofFIG. 2 in an open position with a connection partially installedtherein.

FIG. 7 is a perspective view of a protected connection assemblyincluding the connection and the sealant-filled enclosure assembly ofFIG. 1 in a closed position.

FIG. 8 is cross-sectional view of the protected connection assembly ofFIG. 7 taken along the line 8-8 of FIG. 7.

FIG. 9 is a perspective view of a sealant-filled enclosure assemblyaccording to further embodiments of the present invention in an openposition.

FIG. 10 is a perspective view of a sealant-filled enclosure assemblyaccording to further embodiments of the present invention in an openposition.

FIG. 11 is a perspective view of a protected connection assemblyincluding a connection and the sealant-filled enclosure assembly of FIG.10 in a closed position.

FIG. 12 is a top plan view of a housing of the sealant-filled enclosureassembly of FIG. 10 in the open position.

FIG. 13 is a cross-sectional view of the sealant-filled enclosureassembly of FIG. 10 taken along the line 13-13 of FIG. 10.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which illustrativeembodiments of the invention are shown. In the drawings, the relativesizes of regions or features may be exaggerated for clarity. Thisinvention may, however, be embodied in many different forms and shouldnot be construed as limited to the embodiments set forth herein; rather,these embodiments are provided so that this disclosure will be thoroughand complete, and will fully convey the scope of the invention to thoseskilled in the art.

It will be understood that, although the terms first, second, etc. maybe used herein to describe various elements, components, regions, layersand/or sections, these elements, components, regions, layers and/orsections should not be limited by these terms. These terms are only usedto distinguish one element, component, region, layer or section fromanother region, layer or section. Thus, a first element, component,region, layer or section discussed below could be termed a secondelement, component, region, layer or section without departing from theteachings of the present invention.

Spatially relative terms, such as “beneath”, “below”, “lower”, “above”,“upper” and the like, may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is turned over, elements described as “below” or “beneath” otherelements or features would then be oriented “above” the other elementsor features. Thus, the exemplary term “below” can encompass both anorientation of above and below. The device may be otherwise oriented(rotated 90° or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly.

As used herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless expressly stated otherwise. Itwill be further understood that the terms “includes,” “comprises,”“including” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof. It will be understood thatwhen an element is referred to as being “connected” or “coupled” toanother element, it can be directly connected or coupled to the otherelement or intervening elements may be present. As used herein, the term“and/or” includes any and all combinations of one or more of theassociated listed items.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of this specification andthe relevant art and will not be interpreted in an idealized or overlyformal sense unless expressly so defined herein.

According to embodiments of the present invention, a sealant-filledenclosure assembly for protecting a connection includes a housingdefining a cavity, and a mass of sealant disposed in the cavity. Thehousing includes at least one gate member that can be selectively brokenaway to open a cable port for entry of a cable into the cavity.

With reference to FIGS. 1-8, a sealant-filled enclosure assembly 100according to some embodiments of the present invention is shown therein.The enclosure assembly 100 is adapted to form a sealed enclosure about aconnection and/or cables or the like. For example, the enclosureassembly 100 may be used to form an environmentally protective enclosureabout a plurality of conductors 12, 14 (e.g., electrical power lines)joined by a connector 16 to form a connection 22 as best shown in FIGS.6 and 8.

With reference to FIGS. 1-5, the sealant-filled enclosure 100 includes ahousing 120 and masses of sealant 110, 114 disposed therein. Accordingto some embodiments, and as discussed in more detail below, the sealant110, 114 may be a gel. The housing 120 includes a first shell or covermember 122 and a second shell or cover member 124 joined to one anotherby a hinge 126 and adapted to move between an open position as shown inFIGS. 1 and 6 and a closed position as shown in FIGS. 7 and 8. In otherembodiments, the cover members 122, 124 are not hinged. In the openposition, the enclosure assembly 100 can receive the connection 22 andadjacent portions of the conductors 12, 14. In the closed position, theenclosure assembly 100, including the masses of sealant 110, 114, mayoperate to seal about and environmentally protect the connection 22. Inthe closed position, the enclosure assembly 100 defines an enclosurecavity 106 (FIG. 8) and opposed pairs of ports 108 (FIGS. 7 and 8)communicating with the enclosure cavity 106.

Turning to the housing 120 in more detail and as best seen in FIGS. 1and 2, the cover members 122, 124 are constructed in generally the samemanner, except for the configurations of the latch structures andplacement relative to the hinge 126. Each cover member 122, 124 includesa bottom wall 130. A dome 130A may be defined in the bottom wall 130.Opposed side walls 132 and opposed gate structures 151, 161 extendupwardly from the bottom wall 130. Opposed pairs of locator ribs 148extend upwardly from the bottom wall 130. Opposed extension portions 140extend longitudinally from either end of each cover member 122, 124.Strain relief features (as shown, tie wrap holes 143) are provided ineach extension 140.

The upper edges of the walls 132, 134 form a perimeter edge 138 definingan opening 138A. The walls 130, 132 of each cover member 122, 124 definean overall cover member chamber or cavity 136. Each extension portion140 defines an extension subchannel 142 having an open end 142A. Thesealants 110, 114 are disposed in the cavities 136 prior to use of theenclosure assembly 100, but, according to some embodiments and as shownin FIG. 1, not in extension subchannels 142.

The cover members 122, 124 are pivotably joined by the hinge 126.According to some embodiments, the hinge 126 is a flexible, livinghinge. A living hinge may allow for unitary formation of the housing120, as well as possible cost savings in materials and assembly.Alternatively, other hinge configurations may be employed. For example,the hinge 126 may be replaced by or supplemented with interlockingpivotally coupled hinge structures and/or a pivot pin. In someembodiments, the cover members 122, 124 may be non-hinged.

Latch structures 144A, 144B are located on the respective sidewalls 132opposite the hinge 126. The latch structures 144A, 144B are adapted tocooperate with one another to permanently or releasably secure thehousing 120 in the closed position.

The gate structures 151 of the cover members 122, 124 collectively forma port control system 150. The gate structures 161 of the cover members122, 124 collectively form a port control system 160.

The gate structure 151 includes side-by-side gate members 152, 154joined to the side walls 132 and a center or divider post 158 byfrangible connection portions 156 (as seen in FIGS. 4 and 5). The gatemembers 152, 154 are aligned with locations where the cables may enterthe enclosure. Notches 156A are provided on the lead ends of eachconnection portion 156 at the top edges of the gate members 152, 154.Each gate member 152, 154 is further pivotally joined to the bottom wall130 by a living hinge 156B (FIGS. 2 and 3).

The gate structure 161 includes side-by-side gate members 162, 164joined to the side walls 132 and a center or divider post 168 byfrangible connection portions 166 (FIG. 2). The gate members 162, 164are aligned with locations where the cables may enter the enclosure.Notches 166A are provided on the top or lead ends of each connectionportion 166 at the top edges of the gate members 162, 164. Each gatemember 162, 164 is further pivotally joined to the bottom wall 130 by aliving hinge 166B.

According to some embodiments, each gate member 152, 154, 162, 164 issubstantially rigid or semi-rigid. According to some embodiments, eachgate member 152, 154, 162, 164 is a unitary panel. According to someembodiments, there are no tear or shear lines in the panels 152, 154,162, 164. According to some embodiments, each gate member 152, 154, 162,164 has a width W greater than the diameter of the largest cableintended to be protected using the enclosure assembly 100. According tosome embodiments, the width W is in the range of from about 0.1 to 4inches. According to some embodiments, the width W is between about 5and 200% greater than the diameter of the largest cable intended to beprotected.

The housing 120 may be formed of any suitable material. According tosome embodiments, the housing 120 is formed of an electricallyinsulative material. In some embodiments, the housing 120 is formed of avacuum formed or molded polymeric material. The housing 120 may beformed of polypropylene, nylon, polyethylene, ABS and/or PMMA. Thehousing 120 may be formed of a flame retardant material. The housingmaterial may be any color or transparent.

The sealants 110, 114 may be any suitable sealants. According to someembodiments, the sealants 110, 114 are gel sealants. As used herein,“gel” refers to the category of materials which are solids extended by afluid extender. The gel may be a substantially dilute system thatexhibits no steady state flow. As discussed in Ferry, “ViscoelasticProperties of Polymers,” 3^(rd) ed. P. 529 (J. Wiley & Sons, New York1980), a polymer gel may be a cross-linked solution whether linked bychemical bonds or crystallites or some other kind of junction. Theabsence of the steady state flow may be considered to be the definitionof the solid-like properties while the substantial dilution may benecessary to give the relatively low modulus of gels. The solid naturemay be achieved by a continuous network structure formed in the materialgenerally through crosslinking the polymer chains through some kind ofjunction or the creation of domains of associated substituents ofvarious branch chains of the polymer. The crosslinking can be eitherphysical or chemical as long as the crosslink sites may be sustained atthe use conditions of the gel.

Gels for use in this invention may be silicone (organopolysiloxane)gels, such as the fluid-extended systems taught in U.S. Pat. No.4,634,207 to Debbaut (hereinafter “Debbaut '207”); U.S. Pat. No.4,680,233 to Camin et al.; U.S. Pat. No. 4,777,063 to Dubrow et al.; andU.S. Pat. No. 5,079,300 to Dubrow et al. (hereinafter “Dubrow '300”),the disclosures of each of which are hereby incorporated herein byreference. These fluid-extended silicone gels may be created withnonreactive fluid extenders as in the previously recited patents or withan excess of a reactive liquid, e.g., a vinyl-rich silicone fluid, suchthat it acts like an extender, as exemplified by the Sylgard® 527product commercially available from Dow-Corning of Midland, Mich. or asdisclosed in U.S. Pat. No. 3,020,260 to Nelson. Because curing isgenerally involved in the preparation of these gels, they are sometimesreferred to as thermosetting gels. The gel may be a silicone gelproduced from a mixture of divinyl terminated polydimethylsiloxane,tetrakis (dimethylsiloxy)silane, a platinum divinyltetramethyldisiloxanecomplex, commercially available from United Chemical Technologies, Inc.of Bristol, Pa., polydimethylsiloxane, and1,3,5,7-tetravinyltetra-methylcyclotetrasiloxane (reaction inhibitor forproviding adequate pot life).

Other types of gels may be used, for example, polyurethane gels astaught in the aforementioned Debbaut '261 and U.S. Pat. No. 5,140,476 toDebbaut (hereinafter “Debbaut '476”) and gels based on styrene-ethylenebutylenestyrene (SEBS) or styrene-ethylene propylene-styrene (SEPS)extended with an extender oil of naphthenic or nonaromatic or lowaramatic content hydrocarbon oil, as described in U.S. Pat. No.4,369,284 to Chen; U.S. Pat. No. 4,716,183 to Gamarra et al.; and U.S.Pat. No. 4,942,270 to Gamarra. The SEBS and SEPS gels comprise glassystyrenic microphases interconnected by a fluid-extended elastomericphase. The microphase-separated styrenic domains serve as the junctionpoints in the systems. The SEBS and SEPS gels are examples ofthermoplastic systems.

Another class of gels which may be used are EPDM rubber-based gels, asdescribed in U.S. Pat. No. 5,177,143 to Chang et al.

Yet another class of gels which may be used are based onanhydride-containing polymers, as disclosed in WO 96/23007. These gelsreportedly have good thermal resistance.

The gel may include a variety of additives, including stabilizers andantioxidants such as hindered phenols (e.g., Irganox™ 1076, commerciallyavailable from Ciba-Geigy Corp. of Tarrytown, N.Y.), phosphites (e.g.,Irgafos™ 168, commercially available from Ciba-Geigy Corp. of Tarrytown,N.Y.), metal deactivators (e.g., Irganox™ D1024 from Ciba-Geigy Corp. ofTarrytown, N.Y.), and sulfides (e.g., Cyanox LTDP, commerciallyavailable from American Cyanamid Co. of Wayne, N.J.), light stabilizers(e.g., Cyasorb UV-531, commercially available from American Cyanamid Co.of Wayne, N.J.), and flame retardants such as halogenated paraffins(e.g., Bromoklor 50, commercially available from Ferro Corp. of Hammond,Ind.) and/or phosphorous containing organic compounds (e.g., Fyrol PCFand Phosflex 390, both commercially available from Akzo Nobel ChemicalsInc. of Dobbs Ferry, N.Y.) and acid scavengers (e.g., DHT-4A,commercially available from Kyowa Chemical Industry Co. Ltd throughMitsui & Co. of Cleveland, Ohio, and hydrotalcite). Other suitableadditives include colorants, biocides, tackifiers and the like describedin “Additives for Plastics, Edition 1” published by D.A.T.A., Inc. andThe International Plastics Selector, Inc., San Diego, Calif.

The hardness, stress relaxation, and tack may be measured using aTexture Technologies Texture Analyzer or like machine, having a loadcell to measure force, a 5 gram trigger, and ¼ inch (6.35 mm) stainlesssteel probe. For measuring the hardness, for example, of a 20 mL glassvial containing 12 grams of gel, the probe is forced into the gel at thespeed of 0.2 mm/sec to a penetration distance of 4.0 mm. The hardness ofthe gel is the force in grams required to force the probe at that speedto penetrate the gel specified for 4.0 mm. Higher numbers signify hardergels.

The tack and stress relaxation are read from the stress curve generatedby tracing the force versus time curve experienced by the load cell whenthe penetration speed is 2.0 mm/second and the probe is forced into thegel a penetration distance of about 4.0 mm. The probe is held at 4.0 mmpenetration for 1 minute and withdrawn at a speed of 2.00 mm/second. Thestress relaxation is the ratio of the initial force (F_(i)) resistingthe probe at the pre-set penetration depth minus the force resisting theprobe (F_(f)) after 1 min divided by the initial force F_(i), expressedas a percentage. That is, percent stress relaxation is equal to

$1.\mspace{14mu} \frac{\left( {F_{i} - F_{f}} \right)}{F_{i\;}} \times 100\%$

where F_(i) and F_(f) are in grams. In other words, the stressrelaxation is the ratio of the initial force minus the force after 1minute over the initial force. It may be considered to be a measure ofthe ability of the gel to relax any induced compression placed on thegel. The tack may be considered to be the amount of force in gramsresistance on the probe as it is pulled out of the gel when the probe iswithdrawn at a speed of 2.0 mm/second from the preset penetration depth.

An alternative way to characterize the gels is by cone penetrationparameters according to ASTM D-217 as proposed in Debbaut '261; Debbaut'207; Debbaut '746; and U.S. Pat. No. 5,357,057 to Debbaut et al., eachof which is incorporated herein by reference in its entirety. Conepenetration (“CP”) values may range from about 70 (10⁻¹ mm) to about 400(10⁻¹ mm). Harder gels may generally have CP values from about 70 (10⁻¹mm) to about 70 (10⁻¹ mm). Softer gels may generally have CP values fromabout 200 (10⁻¹ mm) to about 400 (10⁻¹ mm), with particularly preferredrange of from about 250 (10⁻¹ mm) to about 375 (10⁻¹ mm). For aparticular materials system, a relationship between CP and Voland gramhardness can be developed as proposed in U.S. Pat. No. 4,852,646 toDittmer et al.

According to some embodiments, the gel has a Voland hardness, asmeasured by a texture analyzer, of between about 5 and 100 grams force.The gel may have an elongation, as measured by ASTM D-638, of at least55%. According to some embodiments, the elongation is of at least 100%.The gel may have a stress relaxation of less than 80%. The gel may havea tack greater than about 1 gram.

While, in accordance with some embodiments, the sealants 110, 114 aregels as described above, other types of sealants may be employed. Forexample, the sealants 110, 114 may be silicone grease orhydrocarbon-based grease.

The enclosure assembly 100 may be formed in the following manner. Thecover members 122, 124 and the hinge 126 may be integrally formed.According to some embodiments, the cover members 122, 124 and the hinge126 are unitarily molded. According to some embodiments, the entirety ofthe housing 120 is unitarily molded. The housing 120 may be injectionmolded or vacuum formed, for example. According to other embodiments(e.g., if the cover members are not hinged), the cover members 122, 124are separately molded or otherwise formed.

If the sealant 110, 114 is a material, such as a curable gel, thatrequires curing, the sealant may be cured in situ.

The enclosure assembly 100 can be used as follows in accordance withmethods of the present invention to form the enclosed connection 24(FIGS. 7 and 8). The connection 22 (FIG. 6) is formed by installing theconnector 16 on the conductors 12, 14. The enclosure assembly 100 isprepared for installation of the conductors by selectively opening orbreaking away one or more of the gate members 152, 154, 162, 164 todefine respective subports through the gate structures 151, 161. Theselected gates may be pre-broken by the operator or may be broken byinstallation of the cables. More particularly, the selected gate members152, 154, 162, 164 are broken away from the center posts 158, 168 andthe side walls 132 and folded down about their lower hinges 156B, 166Bto open the subports. For example, in the illustrated embodiment of FIG.6, the gate members 152, 154, 162 have each been broken open to open thesubports 152A, 154A, 162A. The notches 156A, 166A may help the user toinitiate splitting, tearing or breach of the frangible connectionportions 156, 166 to release the selected gate members 152, 154, 162,164 from the center posts 158, 168 and the side walls 132. Typically,the gate members 152, 154 and the gate members 162, 164 will be openedas matched opposed (e.g., top and bottom) pairs (i.e., the gate members152 of each cover member 122, 124 as a set, the gate members 154 of eachcover member 122, 124 as a set, the gate members 162 of each covermember 122, 124 as a set, and/or the gate members 164 of each covermember 122, 124 as a set).

Thereafter, the enclosure assembly 100 is installed over the connection22 and portions of the conductors 12, 14. The enclosure assembly 100 maybe held in a fully or partially open position as shown in FIG. 6 and theconnection 22 may be inserted between the cover members 122, 124. Theenclosure assembly 100 is then closed by urging one or both of the covermembers 122, 124 to relatively pivot about the hinge 126 into engagementas shown in FIG. 7, such that the latch structures 144A, 144B are madeto lock in the closed position. Securing members, such as tie wraps T orthe like, may be installed through the tie wrap holes 143 to secure theconductors 12, 14 in place and provide strain relief for the conductors12, 14.

The closed housing 120 defines an enclosure cavity 106 (FIG. 8). Theextension portions 140 of the cover members 122, 124 combine to formopposed tubular extensions 146. Each tubular extension 146 defines arespective sealant collection and control chamber or reservoir 109having an end opening 109A (formed from the extension subchannels 142and end openings 142A, collectively). Additionally, the open subports152A, 154A, 162A combine to collectively define cable ports 152B, 154B,162B (FIG. 7).

Upon closure of the enclosure assembly 100, the connection 22 isencapsulated within the sealant 110, 114, and the sealant 110, 114 andthe connection 22 are in turn encapsulated within the housing 120 (i.e.,contained within the enclosure cavity 106). The cables 12, 14 extendthrough the cable ports 152B, 154B, 162B, respectively. The gate members164 remain in their closed position to prevent or inhibit the sealant110, 114 from exuding out of the cavity 106 at their location.

As the enclosure assembly 100 is closed, the sealant 110, 114 isforcibly displaced by the connector 16 and the cables 12, 14, causingthe sealant 110, 114 to flow out of the cavity 106, through the cableports 152B, 154B, 162B, and into the extension reservoirs 109 as shownin FIG. 8. The sealant mass 116 overflowed or exuded out through thecable ports 152B, 154B, 162B is collected and retained by thesurrounding walls of the extensions 146.

According to some embodiments and as illustrated, the volumes andconfigurations of the sealants 110, 114 are selected to ensure that theconnection 22 displaces at least one, and according to some embodiments,both of the sealants 110, 114 when the enclosure assembly 100 istransitioned from the open position to the closed position with theconnection 22 disposed therein. According to some embodiments, thecombined volume of the connector 16, the portions of the conductors 12,14 in the enclosure cavity 106, and the sealants 110, 114 is greaterthan the volume of the enclosure cavity 106.

As discussed above, according to some embodiments, each gate member 152,154, 162, 164 is substantially rigid or semi-rigid. According to someembodiments, the stiffness of each gate member 152, 154, 162, 164 issufficient to withstand a pressure from the interior side (i.e., thecavity 136 side) of at least 3 psi, and according to some embodiments atleast 8 psi, without deforming or deflecting an amount sufficient topermit the sealant 112, 114 to pass through the corresponding cable port152B, 154B, 162B, 164B.

According to some embodiments, the connection(s) between each gatemember 152, 154, 162, 164 and the housing 120 (e.g., the frangibleconnection portions 156, 166) are sufficient to require at least 3 psi,and according to some embodiments at least 8 psi, of pressure on theinterior side to break the gate member 152, 154, 162, 164 away and openthe corresponding port 152B, 154B, 162B, 164B. According to someembodiments, a minimum gate opening force of at least 3 pounds-force,and according to some embodiments at least 8 pounds-force, must beapplied to the gate member 152, 154, 162, 164 in order to open the gatemember. This gate opening force may be applied by laying a cable 12, 14over the gate member and forcing the cover members 122, 124 closed, byapplying a load to the gate member by hand or using a tool to pre-breakthe frangible connection portions 156, 166, or by any other suitablemethod. According to some embodiments, the required gate opening forceis selected such that an unopened gate member 152, 154, 162, 164 (i.e.,a gate member having its frangible connection portions 156, 166 intact)will not be forced open by the internal pressure of the sealant 110, 114during installation or in service with a connection within theprescribed size range, but can be deliberately broken away and openedwithout undue force.

By provision of the gate structures 151, 161, the enclosure assembly 100may ensure that the housing 120 can be closed without requiring undueforce, but nonetheless that the sealants 110, 114 are displaced andforced to flow about the connection 22 and the sealants 110, 114sufficiently engage with one another at the interface between the covermembers 122, 124. More particularly, the sizes of the open cable ports152B, 154B, 162B are controlled for both egress of the sealant 110, 114from the cavity 106 and ingress into the cavity 106. The sizes of theopen cable ports 152B, 154B, 162B are well-defined and the gate members152, 154, 162, 164 that are not opened are sufficiently rigid (e.g.,free of shear lines) to substantially prevent sealant from passingthrough those locations. The open cable ports 152B, 154B, 162B may besomewhat larger than the cables 12, 14 extending therethrough so that anenlarged exit area is provided. The enlarged exit area can permit thesealant 110, 114 to flow outwardly through the open ports 152B, 154B,162B due to thermal expansion of the sealant 110, 114, and also permitthe sealant 110, 114 to return flow back into the cavity 106 through theopen ports 152B, 154B, 162B due to thermal contraction. The returnedsealant can thus again provide the desired internal compressive forceand sealing advantage within the cavity 106.

The extensions 146 can also enable or facilitate closure and effectiveinstallation of the enclosure assembly 100. The walls of each extension146 can confine the overflowed sealant 116 to retain the sealant 116within the housing 120. The extension reservoirs 109 may effectivelyfunction as extensions of the cavity 106, albeit on sides of the gatestructures 151, 161 and cable ports 152B, 154B, 162B opposite the cavity106. In this manner, the extension 146 may protect the sealant 116 andallow the sealant 116 to be confined to a specified volume duringthermal expansion.

As will be appreciated from the description herein, the sealant 110, 114engages portions of the conductors 12, 14 to form seals thereabout. Thesealant 110, 114 also forms a sealing block that surrounds the connector16, thereby sealing the connector 16. Notably, in the illustratedenclosure assembly 100, the sealants 110, 114 connect with one anotherto encapsulate the connector 16 and conductors 12, 14.

The enclosure assembly 100 may be sized and configured to accommodateand seal multiple or a range of sizes of connectors 16 and conductors12, 14.

While two gate members 152, 154, 162, 164 are provided at each end ofthe housing 120, more or fewer gate members (and thereby more or fewerdefined ports) may be provided. For example, one or both ends mayinclude three or more gate members connected by intervening rigid posts158, 168. In some embodiments, one or both ends are provided insteadwith only a single gate member to provide only a single available cableport, and the single gate member may fully span the distance between theopposed side walls 132.

The enclosure assembly 100 may provide a number of advantages. Theenclosure assembly 100 may provide a reliable seal about the connection22. This seal may prevent or inhibit the ingress of moisture that wouldotherwise cause corrosion of the connection 22. The sealant 110, 114,particularly gel sealant, may accommodate conductors of different sizeswithin a prescribed range. The interfacing sealant masses 110, 114 andthe relationship between the connector or connection volume and thesealant volumes may ensure that a suitable seal is provided by andbetween the sealants for a broadened range of size connections 22positioned in the enclosure assembly 100.

When the sealant 110, 114 is a gel, the conductors 12, 14 and thehousing 120 may apply a compressive force to the sealant 110, 114 as theassembly 100 is transitioned from the open position to the closedposition. The gel may thereby be elongated and be generally deformed andsubstantially conform to the outer surfaces of the connector 16, theconductors 12, 14 and to the inner surface of the housing 120. Someshearing of the gel may occur as well. At least some of the geldeformation may be elastic. The restoring force in the gel resultingfrom this elastic deformation generally causes the gel to operate as aspring exerting a force between the housing 120 and the connector 16 andthe conductors 12, 14. The compressive loading and restoring force aremaintained by the closure of the cover members 122, 124.

Various properties of the gel as described above may ensure that the gelsealant 110, 114 maintains a reliable and long lasting seal between thehousing 120 and the connector 16 and the conductors 12, 14. The elasticmemory of and the retained or restoring force in the elongated,elastically deformed gel generally cause the gel to bear against themating surfaces of the connector 16, the conductors 12, 14 and theinterior surface of the housing 120. Also, the tack of the gel mayprovide adhesion between the gel and these surfaces. The gel, eventhough it is cold-applied, is generally able to flow about the connector16, the conductors 12, 14 and the housing 120 to accommodate theirirregular geometries.

According to some embodiments, the sealant 110, 114 is a self-healing orself-amalgamating gel. This characteristic, combined with theaforementioned compressive force between the connector 16, conductors12, 14 and the housing 120, may allow the sealant 110, 114 to re-forminto a continuous body if the gel is sheared by the insertion of theconductors 12, 14 into the enclosure assembly 100. The gel may alsore-form if the connector 16 and conductors 12, 14 are withdrawn from thegel.

The sealant 110, 114, particularly when formed of a gel as describedherein, may provide a reliable moisture barrier for the conductors 12,14 and the connector 16, even when the enclosure assembly 100 issubjected to extreme temperatures and temperature changes. The housing120 may be made from an abrasion resistant material that resists beingpunctured by the abrasive forces.

The gel sealant may also serve to prevent or inhibit corrosion of theconnection 22 by depositing a layer of oil from the gel on the exposedsurfaces of the connector 16 and conductor portions 12, 14 in theenclosure cavity 106. Even if the gel is removed from the connection 22,the oil may remain to coat the connection surfaces as a barrier tomoisture.

As will be appreciated from the description herein, enclosure assembliesaccording to the present invention may be provided as pre-formed andfully assembled units, with pre-cured gel or other sealant therein asdescribed above, that may be cold applied about a connection to form aseal.

While, in accordance with some embodiments, the housing 120 isintegrally and unitarily formed, the housing may be otherwise formed inaccordance with some aspects of invention. For example, the covermembers 122, 124 and/or the hinge 126 may be separate parts joinedtogether in hinged fashion or otherwise. For example, the cover members122, 124 may be separate pieces secured together by tie wraps, snaps,latches or the like and/or not hinged.

It will be appreciated that enclosures in accordance with the presentinvention may have components (e.g., cover members, walls, etc.) andcavities or chambers having shapes, configurations and/or sizesdifferent than those shown and described herein.

According to some embodiments, the conductors 12, 14 are powertransmission conductors. According to some embodiments, the conductors12, 14 are aerial power transmission conductors. According to someembodiments, the conductor 14 is a main line electrical conductor andthe conductor 12 is a tap line electrical conductor. According to someembodiments, the conductors 12, 14 each include a plurality of elongatestrands (e.g., helically wound strands). According to some embodiments,the conductors 12, 14 are signal transmission conductors. The conductors12, 14 may be insulated or uninsulated.

With reference to FIG. 9, a sealant-filled enclosure assembly 200according to further embodiments of the present invention will now bedescribed. The enclosure assembly 200 includes sealant 210, 214,corresponding to the sealant 110, 114, and a housing 220. The enclosureassembly 200 differs from the enclosure assembly 100 in that the housing220 has fixed, solid end walls 235 opposite gate structures 251corresponding to the gate structures 151. The gate structures 251include gate members 252, 254 that can be selectively opened asdiscussed above to provide cable ports. The enclosure assembly 200 canbe used to cover a pigtail or stub connection, for example.

With reference to FIGS. 10-13, a sealant-filled enclosure assembly 300according to further embodiments of the present invention will now bedescribed. The enclosure assembly 300 corresponds to the enclosureassembly 100 except that the housing 320 of the enclosure assembly 300further includes end walls 347 on each cover member 322, 324 across theends of the extension portions 340. When the housing 320 is closed, theend walls 347 combine to form opposed end walls 349 (FIG. 11) spacedapart from the gate structures 351, 361. According to some embodiments,the end walls 347 are frangible. For example, the end walls 347 maycomprise a series of narrow fingers joined by relatively thin, tearablemembranes.

In use, the installed conductors 12, 14 will break or splay thefrangible walls 347 so that the conductors pass therethrough and aregenerally surrounded thereby. The end walls 347 may be angled outwardlyso that they tend to be splayed outwardly by the conductors. Thecombined end walls 349 (FIG. 11) aid in preventing or impeding outsideobjects from entering the housing 320 along the conductor.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention as defined inthe claims. In the claims, means-plus-function clauses are intended tocover the structures described herein as performing the recited functionand not only structural equivalents but also equivalent structures.Therefore, it is to be understood that the foregoing is illustrative ofthe present invention and is not to be construed as limited to thespecific embodiments disclosed, and that modifications to the disclosedembodiments, as well as other embodiments, are intended to be includedwithin the scope of the appended claims. The invention is defined by thefollowing claims, with equivalents of the claims to be included therein.

1. A sealant-filled enclosure assembly for environmentally protecting aconnection between cables, the sealant-filled enclosure assemblycomprising: a housing selectively configurable between an open positionto receive the connection and a closed position wherein the housingdefines an enclosure cavity to contain the connection, wherein thehousing includes: at least one sealant cavity; and a port control systemincluding a gate member that is selectively deflectable from a closedposition, wherein the gate member blocks a cable port, to an openposition, wherein the cable port is open to permit a cable to extendinto the enclosure cavity through the cable port; wherein the gatemember is rigid or semi-rigid; and a mass of sealant disposed in the atleast one sealant cavity.
 2. The sealant-filled enclosure assembly ofclaim 1 wherein the gate member has a minimum gate opening forcerequired to deflect the gate member from the closed position to the openposition of at least 3 pounds-force.
 3. The sealant-filled enclosureassembly of claim 1 wherein the gate member is a unitary gate panel. 4.The sealant-filled enclosure assembly of claim 3 wherein the gate memberis free of tear and shear lines.
 5. The sealant-filled enclosureassembly of claim 1 wherein the gate member has a gate width greaterthan the diameter of the largest cable intended to be protected usingthe sealant-filled enclosure assembly.
 6. The sealant-filled enclosureassembly of claim 5 wherein the gate width is between about 5 and 200percent greater than the diameter of the largest cable intended to beprotected using the sealant-filled enclosure assembly.
 7. Thesealant-filled enclosure assembly of claim 1 wherein: the housingdefines, when closed, a tubular extension defining a reservoir on a sideof the gate member opposite the enclosure cavity; and the tubularextension is configured to collect and retain in the reservoir sealantexuded from the enclosure cavity through the cable port.
 8. Thesealant-filled enclosure assembly of claim 7 wherein the tubularextension has an end opening to receive entry of the cable and the endopening is open and unblocked.
 9. The sealant-filled enclosure assemblyof claim 7 wherein the tubular extension has an end opening to receiveentry of the cable and the housing includes a frangible end wallextending across the end opening and spaced apart from the gate member.10. The sealant-filled enclosure assembly of claim 1 wherein the housingincludes a cover member and the gate member is integrally and unitarilymolded with the cover member.
 11. The sealant-filled enclosure assemblyof claim 10 wherein the gate member is joined to the cover member by aliving hinge and is pivotable about the living hinge between a closedposition and an open position.
 12. The sealant-filled enclosure assemblyof claim 10 wherein: the gate member is joined to the cover member inthe closed position by a frangible connection portion; and the frangibleconnection portion must be torn in order to deflect the gate member fromits closed position to its open position.
 13. The sealant-filledenclosure assembly of claim 12 including a notch located at a leadingend of the frangible connection portion to facilitate tearing of thefrangible connection portion.
 14. The sealant-filled enclosure assemblyof claim 1 wherein the port control system further includes a secondgate member that is selectively deflectable from a closed position,wherein the second gate member blocks a second cable port, to an openposition, wherein the second cable port is open to permit a second cableto extend into the enclosure cavity through the second cable port. 15.The sealant-filled enclosure assembly of claim 14 wherein the first andsecond gate members and the first and second cable ports are located onthe same side of the enclosure cavity.
 16. The sealant-filled enclosureassembly of claim 15 wherein: the housing includes a rigid divider post;and the first and second gate members are separated and connected by therigid divider post.
 17. The sealant-filled enclosure assembly of claim 1wherein: the housing includes first and second cover members that, whenclosed, collectively define the enclosure cavity and the cable port; thefirst gate member is located on the first cover member; and the portcontrol system further includes a second gate member located on thesecond cover member; when the first and second cover members are closed,the first and second gate members are disposed opposite one another tocollectively define the cable port when each of the first and secondgate members is deflected into its open position.
 18. The sealant-filledenclosure assembly of claim 1 configured such that, when the housing isclosed about the connection, the connection will displace an overflowportion of the sealant mass from the enclosure cavity.
 19. Thesealant-filled enclosure assembly of claim 1 wherein the sealant is anelastically elongatable gel.
 20. A method for environmentally protectinga connection between cables, the method comprising: providing asealant-filled enclosure assembly including: a housing selectivelyconfigurable between an open position to receive the connection and aclosed position wherein the housing defines an enclosure cavity tocontain the connection, wherein the housing includes: at least onesealant cavity; and a port control system including a gate member thatis selectively deflectable from a closed position, wherein the gatemember blocks a cable port, to an open position, wherein the cable portis open; wherein the gate member is rigid or semi-rigid; and a mass ofsealant disposed in the at least one sealant cavity; selectivelydeflecting the gate member to its open position to open the cable port;installing the connection in the enclosure cavity such that the cableextends into the enclosure cavity through the cable port; and closingthe housing about the connection.
 21. A sealant-filled enclosureassembly for environmentally protecting a connection between cables, thesealant-filled enclosure assembly comprising: a housing selectivelyconfigurable between an open position to receive the connection and aclosed position wherein the housing defines an enclosure cavity tocontain the connection, wherein the housing includes: at least onesealant cavity; and a port control system including a gate member thatis selectively deflectable from a closed position, wherein the gatemember blocks a cable port, to an open position, wherein the cable portis open to permit a cable to extend into the enclosure cavity throughthe cable port; and a mass of sealant disposed in the at least onesealant cavity; wherein: the housing defines, when closed, a tubularextension defining a reservoir on a side of the gate member opposite theenclosure cavity; and the tubular extension is configured to collect andretain in the reservoir sealant exuded from the enclosure cavity throughthe cable port.
 22. The sealant-filled enclosure assembly of claim 21wherein the tubular extension has an end opening to receive entry of thecable, and the housing includes a frangible end wall extending acrossthe end opening and spaced apart from the gate member.